Tampon overwrap

ABSTRACT

A packaged elongate intravaginal device has an overwrap substantially enclosing the device. The overwrap has a longitudinal overlap seam disposed generally parallel to the longitudinal axis. The seam includes one ply of overwrap material disposed at a first margin of a overwrap blank superposed on a second ply of overwrap material disposed at a second margin of the overwrap blank, opposite the first. The overwrap has a substantially continuous line of weakness that intersects a plane including the longitudinal axis of the packaged device at at least three unique locations. The line of weakness extends across the longitudinal overlap seam and includes weakness components superposed in each ply of the overlap seam, and the line of weakness is arranged and configured in a manner to permit the overwrap to remain as a unitary structure upon destruction of the line of weakness.

This application claims the benefit of U.S. provisional application61/118,046 filed on Nov. 26, 2008, the complete disclosure of which ishereby incorporated herein by reference for all purposes.

Field of the Invention

The present invention relates to a wrapper for an individual absorbentarticle such as a tampon. In particular, the invention relates to atampon wrapper provided with opening means that allows for removal ofthe tampon from the wrapper while keeping the wrapper as a unitary pieceof material. The invention also includes a method of sealing the domeend of the tampon compatible with the opening means.

BACKGROUND OF THE INVENTION

Individual absorbent articles for personal hygiene articles areprotected from the environment by sheets of material commonly referredto as wrappers or overwrap. Tampons, in particular, have employedwrappers in which each tampon is encased in a separate primary package,which may be then be sold in quantity in secondary packaging often abox.

Tampons are generally categorized in two classes: applicator tampons anddigital tampons. The wrapper for an applicator tampon is typicallyelongated, loose, and flange or fin sealed at the ends with a small cutor notch at one end which the user uses to tear open the wrapper in alongitudinal fashion. The wrapper for a digital tampon is typicallytight fitting, often contacting the outer surface of the tamponcompletely about the perimeter and sealed against the tampon at both theinsertion and withdrawal end. This tight wrapping may help maintain theshape of the tampon and prevent deformation.

Over the years there have developed many issues with the wrappers fordigital tampons. Sometimes the tampon has “relaxed” after compressionand is difficult to remove from a wrapper due to the snugness of thefit. Some wrapper materials may actually stick to the outer surface ofthe tampon and be difficult to remove due to material interaction,causing the user to pry off the overwrap from the tampon. See, forexample, WO 2004/080362. Other times, depending on the choice ofmaterial for the wrapper, there may be a static charge to the wrapperwhich causes the pieces of the wrapper to cling to the user's fingersafter the wrapper seal has been broken and the tampon removed.Additionally, when a wrapper is separated into multiple pieces, it isannoying to have to keep those pieces together in one hand while tryingto insert the tampon with the other hand.

Therefore, what is needed is a wrapper that can be removed from theenclosed tampon without difficulty and without the wrapper separatinginto multiple pieces of material.

SUMMARY OF THE INVENTION

We have found a packaged elongate intravaginal device that allows forremoval of the device from the wrapper while keeping the wrapper as aunitary piece of material.

In one embodiment of the invention, a packaged elongate intravaginaldevice has an overwrap substantially enclosing the device. The overwraphas a longitudinal overlap seam disposed generally parallel to thelongitudinal axis. The seam includes one ply of overwrap materialdisposed at a first margin of a overwrap blank superposed on a secondply of overwrap material disposed at a second margin of the overwrapblank, opposite the first. The overwrap has a substantially continuousline of weakness that intersects a plane including the longitudinal axisof the packaged device at at least three unique locations. The line ofweakness extends across the longitudinal overlap seam and includesweakness components superposed in each ply of the overlap seam, and theline of weakness is arranged and configured in a manner to permit theoverwrap to remain as a unitary structure upon destruction of the lineof weakness. Preferably, at least a section of the line of weaknessextends substantially continuously from the first margin of the overwrapblank to the second margin of the overwrap blank. In addition, the lineof weakness may originate proximate a first end of the packaged deviceand extend toward a second end, opposite the first, of the packageddevice. In another preferred embodiment, the line of weakness isinclined about 15° to about 45°.

In another embodiment, a packaged elongate intravaginal device has anoverwrap substantially enclosing the device, and the overwrap has asubstantially continuous line of weakness disposed about the devicehaving an angle to a plane perpendicular to the longitudinal axis of thepackaged device of about 20° to about 35°. The line of weaknessoriginates proximate a withdrawal end of the packaged elongateintravaginal device with a ratio of open length to land length along theline of weakness of about 1:1 and a ratio of open length to land lengthalong the line of weakness distal the withdrawal end of less than about2:1.

In another embodiment of the invention, a method of opening a packagedelongate intravaginal device including the steps of: grasping aninsertion end and a withdrawal end of the packaged elongate intravaginaldevice; twisting the ends in opposite directions about the longitudinalaxis to fracture or otherwise rupture the line of weakness whilemaintaining the unitary structure of the overwrap; removing thewithdrawal end of the overwrap from the elongate intravaginal device;grasping the withdrawal end of the elongate intravaginal device;removing the overwrap from the insertion end of the elongateintravaginal device; and inserting the elongate intravaginal device intoa vagina. The overwrap preferably substantially encloses the device.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of a tampon of the prior art.

FIG. 2 is a plan view of one embodiment of the present invention showinga sheet of overwrap material including weakness components.

FIG. 3 is a perspective view of a wrapped tampon made from the sheet ofmaterial of FIG. 2 according to the present invention.

FIG. 4 is a plan view of an embodiment showing the longitudinal axis anda plane, which is perpendicular to the longitudinal axis.

FIG. 5 is a plan view of another embodiment of the present inventionshowing a sheet of overwrap material including weakness components.

FIG. 6 is a perspective view of a wrapped tampon made from the sheet ofmaterial of FIG. 5 according to the present invention.

FIG. 7 is a plan view of still another embodiment of the presentinvention showing a sheet of overwrap material including weaknesscomponents.

FIG. 8 is a perspective view of a wrapped tampon made from the sheet ofmaterial of FIG. 7 according to the present invention.

FIG. 9 is a plan view of still another embodiment of the presentinvention showing a sheet of overwrap material including weaknesscomponents and a coating.

FIG. 10 is a side elevation of the machine twist direction of therounded end of the over wrapped tampon.

FIG. 11 is a side elevation of the finished packaged tampon of FIG. 10.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Absorbent tampons usually incorporate elongate compressed absorbentstructures, such as substantially cylindrical masses of compressedabsorbent material having a central longitudinal axis and a radius thatdefines the outer circumferential surface of the tampon. Tampons areoften formed by first obtaining a shaped mass of absorbent materialcalled a tampon blank. This blank can be in the form of a roll ofsheet-like material, a segment of a continuous absorbent material, amass of randomly or substantially uniformly oriented absorbent material,an individually prepared or cast mass of absorbent material, and thelike.

The tampon blank is relatively uncompressed and has a relatively lowdensity. It is then compressed to form a product having overalldimensions less than those of the blank prior to use. The compressedtampons may have a generally uniform density throughout the tampon orthey may have regions of differing density as described in Friese etal., U.S. Pat. No. 6,310,296, and Leutwyler et al., U.S. Pat. No.5,911,712, the disclosures of which are herein incorporated byreference. Tampons also usually include a cover or some other surfacetreatment and a withdrawal string or other removal mechanism.

By ‘outer surface’ of the tampon it is meant herein the visible surfaceof the compressed tampon prior to use or expansion.

By ‘length’ of a tampon it is meant herein the linear extension of atampon along its largest dimension.

By ‘perimeter’ of a tampon it is meant herein the distance measuredalong the outer surface of the tampon in a portion of said outer surfaceextending in a plane being substantially perpendicular to the dimensionof the length of said tampon. In other words, the length of the tamponextends along the x-axis of an orthogonal Cartesian coordinate systemand the perimeter typically lies in the y,z-plane of said coordinatesystem. While the exact measurements are not critical, examples ofnominal diameters for tampons suitable in this invention range from 9 to20 mm. Additionally, nominal lengths may be 40 to 60 mm.

The term “overwrap” as used herein refers to a structure, which isformed of a sheet of material and which substantially encloses anindividual intravaginal device.

The term “intravaginal device” may mean those devices designed to beplaced within the vaginal canal such a tampon, or incontinent/pessarydevice.

As used herein, the terms “weakness component” and “line of weakness”shall mean a series of weakness elements arranged in a row. Theseweakness elements may be perforations, areas of reduced thickness,slits, score lines, areas of reduced density, etc. The line of weaknessmay be perforated mechanically or scraped ultrasonically or with alaser.

An example of a packaged tampon 6 known in the prior art is illustratedin FIG. 1. The packaged tampon 6 contains tampon 10 within an overwrap30. Tampon 10 has a compressed, elongate absorbent structure 12 havingan insertion end 14, a withdrawal end 18 and a central portion 16located between the insertion end and withdrawal end. Tampon 10 has anouter surface 20 and perimeter 102, which extends 360° around thetampon.

In the example shown in FIG. 1, the overwrap 30 has an openingmechanism. In this example of prior art, the overwrap has a finger lifttab 32, which allows the user to tear open the overwrap along perforatedlines 34 and 36 that extend around the overwrap. Typically, this type ofopening mechanism results in the overwrap being torn into multipleportions—a central portion having a width which corresponds to thefinger lift dimension, a portion covering the insertion end and aportion covering the withdrawal end. Once the user has opened theoverwrap by lifting and separating the finger lift tab, the user mayadditionally have to peel off the remaining portions. This remains aninconvenience for the user as she now has to use both hands to unwrapthe tampons while dealing with the multiple pieces, which may havestatic charges causing the pieces to cling to her hands, her fingers,and/or the tampon. This can increase the risk of the overwrap remainingon the tampon when it is inserted into the user's body. This remainingpiece of overwrap may disengage from the tampon as the tampon absorbsfluid, thereby remaining in the body until removed by the user.

This uncontrolled opening of the wrapper may also occur in thinnerpackaging materials in which the tear may not follow a predeterminedpath along a line of weakness and may also result in multiple pieces ofthe destroyed wrapper.

The wrappers can generally be formed of a sheet or one connected pieceof overwrap material, though an overwrap can be made from multiplepieces of material sufficiently joined together such that theysubstantially act as a single sheet or one connected piece of overwrapmaterial. In the prior art example of FIG. 1, the material is joinedtogether by any means known in the art. Where the material is joined iscommonly referred to as a seam. The overwrap may be clear, colored, orhave printed graphics which may include directions for opening (arrows,dotted lines, etc.). Typically, suitable wrapper materials for useherein are flexible polymeric films and may have any thickness.Additionally, the surface of the overwrap including the seam may haveprinting. When printing on the overwrap, including the seam, theperforations may become more distinct to the user.

Turning to FIG. 2, there is shown a sheet of overwrap, which is used toform one embodiment of the present invention.

As shown in this figure, the wrapper may be formed from a rectangularsheet of material 40 having an insertion end 42, a withdrawal end 46, acentral portion 44, a first margin 52 and a second margin 54. Thecentral portion 44 further has upper central area 44 a, which is towardthe insertion end and lower central area 44 b, which is toward thewithdrawal end. When sheet 40 is formed into a tube, margins 52 and 54overlap. These margins may be joined together longitudinally (resultingin a seam down the side of the tampon). The sealing of the margins forma two layer seam.

In this embodiment, there is a single line of weakness made of weaknesscomponents 66 and 63. In the embodiment shown in FIG. 2, weaknesscomponent 66 is shown as inclining or at a diagonal direction. A tamponcontained with the resultant overwrap is shown in FIG. 3.

Additionally by using a specific ratio of weakness:land lengths inspecific areas of the overwrap, it is possible to provide an overwrapthat opens completely around the tampon, remains in a single unitarypiece but provides for hygienic removal of the tampon from the overwrap.For example, using a slit or perforation having an open length as theweakness element, it has been found that a ratio in the range, forexample, of approximately 1:1, e.g, about 2:3 to about 3:2, preferablyabout 4:5 to about 5:4 open length:land length in lower central area 44b (including weakness component 63) and a ratio, for example, of openlength to land length in upper central area 44 a of at least about 2:1allows for the user to grasp the insertion end and the withdrawal endwith fingers from both hands, twist, pull, and/or bend on the overwrapand open the upper central area 44 a with a small amount of force. Theuser would then continue to slightly twist the overwrap to further splitthe line of weakness into the lower central area 44 b. The user can thenpull to remove the overwrap from the base with one hand while holdingthe insertion end. The overwrap on the insertion end remains intactwithout the user's fingers contacting the tampon. The overwrap remainsas a single piece of material. Since the perforations in the uppercentral area 44 a have a greater open length as compared to the openlength of the lower central area 44 b, the line of weakness willgenerally open first in the upper central area 44 a (corresponding to acentral portion of the packaged tampon) before opening in the lowercentral area 44 b (corresponding to the lower end of the packagedtampon). The insertion end of the tampon would remain in the overwrapuntil the user completely removed the overwrap (just prior to insertioninto the body). Of course, the steps of twisting open and pulling offthe overwrap can be accomplished in one step. While the above details anexample of a ratio for one type of material, the choice of material andbasis weight can alter the ratio of open area to land region. The aboveprovides examples of open lengths, land lengths and the ratios betweenthem. In one embodiment, the open length:land length ratio is balancedso the formed line of weakness is stronger at withdrawal end and weakerin center portion of the packaged tampon. In another embodiment, theopen length;land length is consistent throughout the perforation line.Any ratio that obtains this is for a particular material and aparticular sized tampon is acceptable, however, the line of weaknessshould be optimized to permit the overwrap to withstand 1) internalexpansion forces from the tampon as the compressed fibers tend to relaxover time and 2) external forces from the environment (such as thoseexerted on the overwrap when a consumer stores the tampon in a purse orpants pocket) without rupturing the line of weakness and 3) processes inmanufacturing. In one preferred embodiment, the twisting force needed torupture the line of weakness is less than about 25 Newtons (“N”).

Weakness components 66 have an open length to land length ratio ofapproximately 2:1 and are located primarily in the upper central area 44a. In one embodiment, the open length to land length in the uppercentral area 44 a is 900:400 (μm) and the open length to land length inthe lower central area 44 b is 450:550 to 500:500 (μm).

Additionally, weakness components 66 may incorporate multiple sets ofopen length to land length to form perforation patterns. For example, inone embodiment starting from lower central area 44, the open length:landlength ratio may be 450:500. As the perforation line enters area 44 a,the open length:land length ratio may become 800:500, then 900:400, andfinally back to 800:500.

The line of weakness does not necessarily have to be straight. As formedin the overwrap, the weakness components and resultant line of weaknessmay be a diagonal line, a curved line or a line that changes directionby e.g. having angles, curves, and/or inflections such as inflectionpoints. In order to obtain the line of weakness in this type ofembodiment, the sheet of material will need to have the weaknesscomponents in the appropriate pattern. In one embodiment, the line ofweakness originates in the withdrawal portion of the tampon and inclinessuch that it terminates in the central portion. In particular, the lineof weakness can be inclined at an angle from the plane perpendicular tothe longitudinal axis. This is shown in FIG. 4 with angle α formed bythe line of weakness to a plane Y-Y extending perpendicular tolongitudinal axis X-X. In another embodiment, the line of weaknessoriginates in the lower 5-25% (lower central area 44 b) of the sheet andterminates in the upper central area 44 a (shown FIG. 2). The angle ofinclination is balanced against the desire to maintain the wrapper in asingle piece. The smaller the angle, the greater the component of forceapplied to the package is translated into shear force that is able torupture the line of weakness. However, a small angle of inclinationprovides greater opportunity for the wrapper material to tear betweenthe ends of the line of weakness to result in two separated packageremnants. The larger the angle, the lesser opportunity for the wrappermaterial to tear between the ends of the line of weakness to result intwo separated package remnants. However, more twisting circumferentialforce may be required to rupture the line of weakness. We have foundthat an angle of about 5° to about 45° is useful and that an angle ofabout 20° to about 35° is preferred to balance the properties discussedabove. As tampons come in varying sizes in order to provide variousabsorbencies, the sheet used to wrap the tampon may have differentdimensions. Often the larger absorbencies will require larger tamponstherefore requiring a larger sheet of overwrap. The zone that isactually perforated will also increase as the size of the overwrap sheetdoes, thereby allowing the line of weakness to traverse a greater area.The perforation zone is that central area 44 shown in FIG. 2. Forexample, with a o.b.® light absorbency tampon (Germany) perforationangle may be 29° which results in a perforation zone that extends for23.5 mm. Using the same angle)(29° for a o.b.® super plus absorbencytampon (Germany) results in a perforation zone of 34 mm. Other examplesare shown in the table below.

TABLE 1 Tampon Angle Perforation Zone (mm) o.b. ® light absorbency 32.527 tampon (Germany) o.b. ® mini tampon 32.5 27 (Germany) o.b. ® normalabsorbency 29 27 tampon (Germany) o.b. ® super absorbency 26 27 tampon(Germany) o.b. ® super plus 23.7 27 absorbency tampon (Germany) o.b. ®light absorbency 29 23.5 tampon (Germany) o.b. ® mini tampon 29 23.5(Germany) o.b. ® normal absorbency 29 27 tampon (Germany) o.b. ® superabsorbency 29 30.5 tampon (Germany) o.b. ® super plus 29 34 absorbencytampon (Germany)

In still another embodiment, the line of weakness is not a straight linebut a curved line that originates in the lower central area 44 b,extends into the upper central area and terminates in the lower centralarea (not shown). In these embodiments, the withdrawal end portion ofthe overwrap is easily removed after the line of weakness has beenruptured, which leaves the insertion portion of the overwrap somewhatintact. This allows the user to further handle the tampon withoutactually contacting or contaminating the insertion end of the tampon.

In a preferred embodiment, the line of weakness according to the presentinvention extends completely around the perimeter of the tampon. As usedherein, the term “extends completely around the perimeter” shall meanthat the line of weakness is continuous 360° about the circumference ofthe outer surface 20 of the intravaginal device.

When placed on a tampon, the overwrap has a continuous line of weaknesswhich includes the two layer seam. The line of weakness thereforeextends completely around the perimeter of the encased tampon. When usedto wrap the tampon, the overwrap has a line of weakness that may haveone end near the withdrawal end 18 of the tampon and another enddisposed toward the insertion end 14. In one embodiment, the line ofweakness is arranged and configured such that when the resultingoverwrap is opened, the portion holding the insertion end of the tamponremains on the tampon and the portion holding the withdrawal end of thetampon also remains on the tampon but can be easily pulled off.

The overlapping of the margins and sealing does not compromise the lineof weakness such that when the user opens the overwrap, the line ofweakness tears completely around and through the sealed overwrap. Theseal does not prevent the line of weakness from extending and performingthrough overlap region. If the line of weakness is formed from a seriesof slits, the forming of the seam in the margins will not close up theslits; rather the slits are sufficiently open to be easily ruptured.

Upon the rupturing of the line of weakness, the resultant open overwrapcan be removed as a unitary piece of material. As the line of weaknessoriginates and end at different parts of the seam, the line of weaknesswill not cause division of the wrapper into separate pieces uponopening. The end and origin of the line of weakness are sufficientlyseparated so as to not overlap.

FIG. 3 shows material sheet 40 wrapped around tampon 10 to form overwrap100. Margins 52 and 54 overlap and are joined to form a two layer seam70. There is one continuous line of weakness 60. The joining of margins52 and 54 to form the two layer seam 70 does not eliminate or close theweakened areas, especially the weakened components.

The seam not only connects the layers of material together but providesa barrier which prevents contaminants from penetrating into the packagedarticle. The seam may be any thickness depending on the materials beingjoined together and the outer conditions. For example, a seal that isexpected to provide water protection may be thicker than a seal used toprevent air penetration (for example, the seal used to wrap dryfoodstuffs). In this invention, the thickness of the seal or seam is notcritical.

Seam 70 may have any dimension that securely holds the overlaid marginstogether. While it is preferred that the edge of the margin forming theouter surface is securely sealed against the lower material, it is notnecessary for the seam to extend to the edge.

In the embodiment shown in FIG. 3, the second margin overlays the firstmargin and partially forms the outer surface of overwrap 100. Theoverwrap is substantially a tube-like cylinder. Both ends are closedsuch that the tampon within the overwrap is completely contained withinthe overwrap and separated from the environment. Seam 70 extends to edge56 of margin 54 and forms a relatively smooth surface. The intravaginaldevice in this figure has longitudinal axis XX, which extends throughinsertion end 42 to withdrawal end 46.

Shown in FIG. 3 is a plane extending outward from and includinglongitudinal axis XX. The line of weakness intersects this plane at atleast three unique locations, as the line of weakness extends at least360° around the perimeter of the tampon. In the embodiment of FIG. 3,the unique locations include where the plane intersects the two weaknesscomponents in the wrapper margins and the weakness component locatedbetween the margins. Thus, the plane intersects the line of weakness atat least three unique locations—m′, m″, m′″.

The longitudinal seam is a longitudinal attachment zone, which connectsthe overlapping margins (52 and 54) together. In this invention, thelongitudinal attachment zone need not be a single, continuous seal linebut rather may be multiple seals lines which are discontinuous andoff-set to each other. This will be further explained below.

In this embodiment, there are two weakness components identified in FIG.2 as elements 63 and 66. Weakness component 63 is mainly in the lowercentral area 44 b of margins 54. In one embodiment, at least one of theweakness component 63 becomes weakness component 66 and extends beyondthe respective margin into the central portion 44. Weakness component 66extends from margin 54 and into margin 52. In the embodiment shown inFIG. 2, weakness component 66 is shown as inclining or at a diagonaldirection. The weakness component may have different characteristics inmargin and central area. In particular, the weakness component in thecentral portion 44 may be weaker than the weakness component in thewithdrawal end 46 of the tampon.

In one embodiment, the ends of the overwrap have a surface textured orembossment. For example, the insertion and withdrawal end may be printedwith a pattern made from an anti-slippery lacquer or may be mechanicallyor ultrasonically embossed such that the ends have a pattern. Thepattern may improve the grip or handling of the packaged tampon.

The seam may be formed by any means known in the art; however, it isimportant as previously stated that the open areas of the line ofweakness not be compromised significantly.

Another example of a sheet of overwrap is shown in FIG. 5. In thisembodiment, there are multiple weakness components, two of which need tobe in the margins. As shown, there are multiple weakness components—62,63, 64 and 66. Weakness component 62 is in margin 52, weaknesscomponents 63 and 64 are in margin 54. Weakness component 66 extendsfrom margin 52 to the edge of margin 54. As in the previous FIG. 2, theweakness components form a single of weakness 60 (shown FIG. 6) whenformed into a tube, which ultimately holds a tampon. The wrapping isdone such that weakened components are registered to each other andoverlap to form one continuous line of weakness 60.

As previously stated, when sheet 40 is formed into a tube for holding atampon, margins 52 and 54 overlap and are joined to form a two layerseam 70. In one embodiment, sheet 40 is a single ply of material suchthat when margins 52 and 54 are overlapped, the two layer seam has twoplies. The wrapping is done such that weakness components are registeredto each other and overlap to form one continuous line of weakness(similar to the packaged tampon shown in FIGS. 3). The joining orsealing of margins 52 and 54 to form the two layer seam does noteliminate or close the weakened areas.

In FIG. 7, another embodiment is shown with the first margin overlayingthe second margin to partially form the outer surface of overwrap 100.In this embodiment, the weakness component begins in margin 154 as ahorizontal line which then inclines diagonally toward margin 152. Inmargin 154, weakness component 164 and in margin 152, weakness component162, each are horizontal and aligned such that when the sheet 140 iswrapped about a cylindrical intravaginal device, they overlay weaknesscomponent 166 to form a continuous line of weakness 160 (shown FIG. 8).Edge 150 of margin 152 partially forms the outer surface of the overwrap100.

While the above details a single line of weakness, it is possible tohave multiple lines of weakness such that the overwrap initially opensin numerous spots in the central portion.

Opening of the wrapper for releasing the tampon 10 along the line ofweakness 160 results in an initial tearing step, during which theoverwrap 100 mainly tears diagonally or at an incline around theperimeter of the tampon 10 and a subsequent step, during which thetampon is removed from the opened overwrap 100. The diagonal opening ofthe overwrap results in a large open area, which allows for the tamponto be easily removed with little manipulation. The opened overwrapremains in a unitary piece, which provides for easy removal and disposalwith one hand. The problem of having multiple small pieces of wrapperclinging to the user's fingers or falling into a toilet is therebyeliminated.

It is generally preferred according to the present invention that thedistance between adjacent weakness elements is substantially equalthroughout the line of weakness. However, if desired, varied spacing canbe employed to affect the tearing force profile (increase/decrease oftearing force upon tear propagation) experienced by the user as sheopens the wrapper along the line of weakness. A particularly preferredembodiment of the line of weakness of the present invention is a line ofweakness extending completely around a part of the perimeter of thewrapped tampon, and in some embodiments, the line of weakness extendsmore around more than the perimeter of the wrapped tampon.

The absorbent materials useful in the formation of the absorbent bodyinclude fiber, foam, superabsorbent, hydrogels, and the like. Preferredabsorbent material for the present invention includes foam and fiber.Absorbent foams may include hydrophilic foams, foams which are readilywetted by aqueous fluids as well as foams in which the cell walls thatform the foam themselves absorb fluid.

The tampon blank may be substantially surrounded or enclosed by afluid-permeable cover. Thus, the cover encloses a majority of the outersurface of the tampon. This may be achieved as disclosed in Friese, U.S.Pat. No. 4,816,100, or Lochte; et al., US Publ. App. No. US 2008-0064581A1, entitled “Tampon Having Apertured Film Cover Thermobonded to FibrousAbsorbent Structure”, the disclosures of which are herein incorporatedby reference. In addition, the insertion end 14 of the tampon, theopposite withdrawal end 18, or both may be enclosed by the cover. Ofcourse, for processing or other reasons, some portions of the surface ofthe tampon 10 may be free of the cover. For example, the insertion end14 of the tampon 10 and a portion of the cylindrical surface adjacentthis end may be exposed, without the cover to allow the tampon 10 tomore readily accept fluids.

The cover may be a nonwoven or apertured polymeric film. The cover canease the insertion of the tampon 10 into the body cavity and can reducethe possibility of fibers being separated from the tampon 10.

Examples for wrapper materials suitable for use with the presentinvention are polymeric films made of polyethylene, polypropylene,polyester, cellophane, polyamide, poly(vinyl chloride), ethylene-vinylacetate copolymer and the like. Alternatively, heat-shrinkable films,stretch films or pre-stretched elastic material can be used to form thewrapper of the present invention. While not limited to a givencomposition, preferred compositions of heat-shrinkable and stretch filmscomprise primarily polyolefins such as polyethylene and polypropylene,or poly(vinyl chloride). Polystyrene and polyethylene-terephtalate(PET), although being not heat sealable, are also suitable for use withthe present invention. In one embodiment of the present invention, thewrapper material is formed from a coextruded polypropylene film.Wrappers consisting of those materials can also be closed by gluing withan adhesive. Other generally occlusive materials include metallic foils,such as aluminum foil. While occlusive wrapper materials are oftenpreferred, in other situations non-occlusive or porous materials can beused, such as nonwovens, wovens, scrims, meshes and papers. Suchnon-occlusive materials can be made occlusive by combinations such as bylamination with or by coating with occlusive material. In the case ofcellulosic papers, examples include lamination with a polymeric filmsuch as a polyolefinic composition or coating or impregnation of thepaper with wax. The aforementioned materials can be coated with variouschemical compounds to improve their barrier properties or the abilityfor sealing. Any suitable combination of the aforementioned materials isalso within the scope of the present invention. In one embodiment, theover wrap material is a matt transparent, heat-sealable, one sidetreated OPP film available from Treofan (Treofan Germany GmbH & Co. KG.Am Prime Parc 17, 65479 Raunheim, Germany) named Treofan Crystal—GNR.

In some embodiments, the materials suitable for use as wrapper materialswith the present invention are heat-sealable for forming the wrapper byclosing the wrapper material via heat-sealing onto itself after havingwrapped the tampon. Thereby a seam is generated in the regions of thewrapper, which were exposed to heat. Alternatives for closing thewrapper material are gluing, embossing, crimping, sewing, stitching,entangling, mechanical interlocking, cold pressure welding, orultrasonic bonding. In some embodiments, the wrapper materials for useherein have a low flexural modulus for providing a low noise tamponwrapper during transport as well as during handling, i.e. opening of thewrapper.

The surface of the over wrap material may be coated to provide asealing/protection to any printing contained on the surface of thesheet. The coating may also aid in providing a frictional grip(increasing the co-efficient of friction, as discussed above) and inprocessing (some inks or coating may result in a sticky surface). In oneembodiment, the overwrap sheet is coated with a finish from SiegwerkDrckfarben AG (Alfred-Keller-Strasse 55, 53721 Siegburg, Germany) soldunder the name of Mr Varnish Masterbatch-MB00. It is important that thecoating does not significantly inhibit the sealing of the overlap seam,or the seam may not be secure enough for the intended use. However, inone embodiment shown in FIG. 9, the line of weakness 200 has acorresponding printed line 202 that overlays or runs adjacent theperforations, even in the margins 204, 206. As the printed line mayextends into at least one margin, the coating also is present in the atleast one margin to help maintain the weakness in the seam area for easyopening.

In currently available tampons, the over wrap may be placed on thetampon as disclosed for example, U.S. Pat. No. 3,856,143 (Simon). Simondiscloses a process and apparatus for twist closing one end of a tubularoverwrap containing a tampon with a rounded head directed toward the endof the wrapper being closed and excess tubular wrapper materialextending past the rounded head. It has been surprising found that thedirection of the overwrap closure twist in relation to the direction ofthe incline of the line of weakness on the overwrap affects theintegrity of the overwrap during further processing. If the twist occursin the direction of a rising line of weakness (e.g. clockwise as shownin FIG. 10), the overwrap is less likely to be weakened than if thetwist were to occur counter-clockwise, as this is the direction theconsumer will twist the package to open it for use. Thus, a tampon 300is enclosed in an overwrap 302 with a line of weakness 304 rising in aclockwise direction. The upper end 306 of the overwrap 302 is twisted ina clockwise direction shown by arrow 308 to form a twist closure 310. Asshown in FIG. 11, the excess material of the upper end 306 of theoverwrap 302 is folded over the domed end 312 of the tampon 300,generally as described in Simon U.S. Pat. No. 3,856,143.

Also included in this invention is a method of opening a tampon packagedwithin an overwrap made according to the description above. In thismethod, the tampon or intravaginal device has a longitudinal axis and issubstantially enclosed by the overwrap, the overwrap has a longitudinaloverlap seam disposed generally parallel to the longitudinal axis andthe overwrap is one ply of material disposed at a first margin of aoverwrap blank superposed on a second ply of overwrap material disposedat a second margin of the overwrap blank, opposite the first, where theoverwrap has a substantially continuous line of weakness that intersectsa plane including the longitudinal axis of the packaged device at atleast three unique locations. The user would grasp the two ends of theintravaginal device and twist, pull and/or bend in opposite directionsin order to rupture the continuous line of weakness. Slightly pulling onthe withdrawal portion of the overwrap, the user removes the overwrap,exposing the central and withdrawal portions of the intravaginal device.The user can then further manipulate the intravaginal device—e.g.,expand the withdrawal end (aids digital insertion). Once this is done,the user can grasp the withdrawal end, remove the overwrap from theinsertion end and insert the tampon into the body cavity.

The specification and embodiments above are presented to aid in thecomplete and non-limiting understanding of the invention disclosedherein. Since many variations and embodiments of the invention can bemade without departing from its spirit and scope, the invention residesin the claims hereinafter appended.

1. A packaged elongate intravaginal device having a longitudinal axiscomprising: a. the elongate intravaginal device; and b. an overwrapsubstantially enclosing the elongate intravaginal device and having alongitudinal overlap seam disposed generally parallel to thelongitudinal axis, wherein: i. the seam includes one ply of overwrapmaterial disposed at a first margin of a overwrap blank superposed on asecond ply of overwrap material disposed at a second margin of theoverwrap blank, opposite the first ii. the overwrap has a substantiallycontinuous line of weakness that intersects a plane including thelongitudinal axis of the packaged device at at least three uniquelocations iii. the line of weakness extends across the longitudinaloverlap seam and includes weakness elements superposed in each ply ofthe overlap seam; and iv. the line of weakness is arranged andconfigured in a manner to permit the overwrap to remain as a unitarystructure upon destruction of the line of weakness.
 2. The packagedelongate intravaginal device of claim 1, wherein at least a section ofthe line of weakness extends substantially continuously from the firstmargin of the overwrap blank to the second margin of the overwrap blank.3. The packaged elongate intravaginal device of claim 1, wherein theline of weakness originates proximate a first end of the packaged deviceand extends toward a second end, opposite the first, of the packageddevice.
 4. The packaged elongate intravaginal device of claim 1, whereinthe line of weakness is inclined about 15° to about 45° from a planeperpendicular to the longitudinal axis.
 5. A packaged elongateintravaginal device having a longitudinal axis comprising: a. theelongate intravaginal device; and b. an overwrap substantially enclosingthe elongate intravaginal device and having a longitudinal overlap seamdisposed generally parallel to the longitudinal axis, wherein: i. theoverwrap has a substantially continuous line of weakness comprising openand land portions, each having a length associated therewith, disposedabout the device having an angle to a plane perpendicular to thelongitudinal axis of the packaged device of about 20° to about 35°; ii.the line of weakness originates proximate a withdrawal end of thepackaged elongate intravaginal device with a ratio of open length toland length along the line of weakness of less than about 3:2 and aratio of open length to land length along the line of weakness distalthe withdrawal end of at least about 2:1.
 6. The packaged elongateintravaginal device of claim 5, wherein the ratio of open length to landlength along the line of weakness proximate the withdrawal end is lessthan about 5:4.
 7. A method of opening an overwrap enclosing an elongateintravaginal device having a longitudinal axis comprising the steps of:a. grasping an insertion end and a withdrawal end of the overwrap, theoverwrap having a substantially continuous line of weakness disposedabout the device having an angle to a plane perpendicular to thelongitudinal axis of the packaged device of about 20° to about 35°; b.rupturing the line of weakness while maintaining the unitary structureof the overwrap; c. removing the withdrawal end of the overwrap from theelongate intravaginal device; d. grasping the withdrawal end of theelongate intravaginal device; e. removing the overwrap from theinsertion end of the elongate intravaginal device; and f. inserting theelongate intravaginal device into a vagina.
 8. The method of claim 7,wherein the step of rupturing the line of weakness comprises twistingthe ends of the overwrap in opposite directions about the longitudinalaxis.
 9. The method of claim 7, wherein the step of rupturing the lineof weakness comprises bending the ends of the overwrap perpendicular tothe longitudinal axis.
 10. The method of claim 7, wherein the step ofrupturing the line of weakness comprises pulling the ends of theoverwrap in opposite directions along the longitudinal axis.
 11. Amethod of sealing the dome end of a tampon overwrap comprising the stepsof: a. forming a tubular overwrap with a longitudinal seam, a first endof the tubular overwrap corresponding to a withdrawal end of the tampon,a second end of the tubular overwrap corresponding to the dome end ofthe tampon, and a line of weakness rising in a first direction towardthe second end of the tubular overwrap; b. closing the first end of thetubular overwrap by folding over and sealing a portion of the tubularoverwrap; c. inserting a tampon into the tubular overwrap; and d.closing the second end of the tubular overwrap by: i. twisting excesstubular overwrap material is extending beyond the dome end of the tamponin the first direction; and ii. folding the excess tubular overwrapmaterial toward the first end of the tubular overwrap and conforming theexcess tubular overwrap material to the dome end of the tampon.
 12. Themethod claim 11, wherein the first direction is clockwise.
 13. Themethod claim 11, wherein the first direction is counterclockwise.